Tampon with an overwrap or overwraps having both masking and wicking properties

ABSTRACT

An improved absorbent catamenial tampon is disclosed comprising an overwrap with both a masking region and a wicking region. The compressed absorbent member of the tampon has an inner region, an exterior surface, and an insertion end opposed to a withdrawal end. The overwrap comprises a masking region and a wicking region. The wicking region of the overwrap covers at least a portion of the exterior surface of the compressed absorbent member proximal to the withdrawal end of the compressed absorbent member. The masking region surrounds at least a portion of the exterior surface of the compressed absorbent member proximal to the insertion end of the compressed absorbent member.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of the and commonly assigned U.S.patent application Ser. No. 10/298,403 filed Nov. 18, 2002, now U.S.Pat. No. 7,112,192 which is a continuation-in-part of commonly assignedU.S. patent application Ser. No. 09/993,988 now U.S. Pat. No. 6,840,927filed Nov. 16, 2001.

FIELD OF THE INVENTION

This invention relates to an improved absorbent tampon with an overwrapor overwraps having both masking and wicking properties that providesenhanced leakage protection, and a clean post-use appearance.

BACKGROUND OF THE INVENTION

A wide variety of absorbent catamenial tampons have long been known inthe art. While it has been found these tampons perform their intendedfunction tolerably well, even the best of tampons do not always providegood coverage against leakage and possess a post-use appearance that hasa negative impact on the consumer. Until recently it was not appreciatedthat post-use appearance of a tampon was an important factor affectingthe consumer's total use experience and that consumers prefer tamponsthat maintain a clean post-use appearance. The design of overwraps orexterior surfaces of a tampon affects a tampon's comfort, as well as,the tampon's post-use appearance. Overwraps designed mainly with thecomfort of the user in mind, reduce the adhesion to vaginal tissue byincluding hydrophobic materials and/or treatments in the design. It wasfound that the same hydrophobic materials that reduce adhesion andincrease comfort might also be more pleasing to the user's perception ofthe tampon, post-use. These hydrophobic overwraps do not retain fluidand thus, yield a tampon with a clean post-use appearance.

While hydrophobic overwraps assist with the post-use appearance, they donot retain fluid, do not assist in the absorbing bypass fluid, orprevent bypass failure. Bypass failure occurs when the menses travelsalong the length of the vagina without contacting the tampon. During atampon change, some residual menses may be left near the introitus ofthe vagina. This may be fluid which was previously absorbed, but whichsubsequently “squeezed out” of the tampon as it was withdrawn throughthe sphincter of the vagina. A replacement tampon may not effectivelyabsorb the residual fluid, particularly if located near the introitus,i.e., in the lower vaginal cavity. Thus, in order to provide a solutiona mechanism must be provided to absorb bypassed fluid from the lowervaginal cavity. One mechanism is to incorporate a wicking region or awicking overwrap into the tampon of the present invention that covers atleast a portion of the exterior surface of the absorbent member andextends beyond the withdrawal end to form a skirt portion.

Accordingly, it would be beneficial to have a tampon that, in additionto providing an improved appearance, can also provide a mechanism toabsorb bypassed fluid from the lower vaginal cavity thereby increasingleakage protection.

BACKGROUND ART

U.S. Pat. No. 6,186,995 issued to John M. Tharpe on Feb. 13, 2001relates to VAGINAL TAMPON AND METHOD FOR FABRICATION THEREOF.

SUMMARY OF THE INVENTION

This invention relates to catamenial tampons having a compressedabsorbent member, and an overwrap comprising a masking region and awicking region. The compressed absorbent member of the tampon has aninner region, an exterior surface, and an insertion end opposed to awithdrawal end. The overwrap comprises a masking region and a wickingregion. The wicking region of the overwrap covers at least a portion ofthe exterior surface of the compressed absorbent member proximal to thewithdrawal end of the compressed absorbent member. The masking regionsurrounds at least a portion of the exterior surface of the compressedabsorbent member proximal to the insertion end of the compressedabsorbent member.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims particularly pointing outand distinctly claiming the subject matter that is regarded as formingthe present invention, it is believed that the invention will be betterunderstood from the following description taken in conjunction with theaccompanying drawings, in which:

FIG. 1 is a perspective view of a tampon of the present inventionincorporating a compressed absorbent member and a masking overwrap, anda wicking overwrap defining a skirt.

FIG. 2 is a plan view of an uncompressed tampon including the absorbentmaterial, masking overwrap and wicking overwrap.

FIG. 3 is a longitudinal cross section of the absorbent material,masking overwrap, and wicking overwrap prior to compression.

FIG. 4A is a plan view of the absorbent material with the maskingoverwrap and the wicking overwrap wrapped longitudinally around theabsorbent material.

FIG. 4B is a plan view of the absorbent material, the masking overwrap,and the wicking overwrap wrapped transversely around the absorbentmaterial.

FIG. 5A is a cross sectional view of the compressed absorbent memberthat is of rolled construction.

FIG. 5B is a cross sectional view of the compressed absorbent memberthat is of folded construction.

FIG. 6 is a perspective view of a tampon of the present inventionincorporating a compressed absorbent member and an overwrap with amasking region and wicking region.

DETAILED DESCRIPTION OF THE INVENTION

As used herein “absorbent material” refers to a construction of theabsorbent matter of a tampon without the overwrap material prior to thecompression.

As used herein “compression” refers to the process of pressing,squeezing, compacting or otherwise manipulating the size, shape, and/orvolume of a material to obtain a tampon having a vaginally insertableshape. The term “compressed” refers to the state of a material ormaterials subsequent to compression. Thus as used herein, the term“compressed absorbent member” refers to the state of the absorbentmaterial subsequent to compression. Conversely, the term “uncompressed”refers to the state of a material or materials prior to compression. Insome embodiments, uncompressed tampons can be utilized in vivo. The term“compressible” is the ability of a material to undergo compression.

The term “folded” as used herein, is the configuration of the compressedabsorbent member that may be incidental to lateral compression of theabsorbent material or may purposely occur prior to a compression step.Such a configuration is readily recognizable, for example, when theabsorbent material abruptly changes direction such that one part of theabsorbent material bends and lies over another part of the absorbentmaterial. When overwrap is placed on the absorbent material prior tocompression, it too may be “folded.”

As used herein “hydrophilic” and “hydrophobic” have meanings wellestablished in the art with respect to the contact angle of a drop ofwater on the surface of a material. For example, a material having acontact angle of greater than about 75 degrees may be consideredhydrophobic, and a material having a contact angle of less than about 75degrees may be considered hydrophilic. Absolute values ofhydrophobocity/hydrophilicity are not generally important, but relativevalues are. Thus, the absorbent member of the tampon and the wickingoverwrap of the present invention are more hydrophilic than the maskingoverwrap, and the masking overwrap is more hydrophobic than theabsorbent member and the wicking overwrap.

The term “joined” or “attached” as used herein, encompassesconfigurations in which a first element is directly secured to secondelement by affixing the first element directly to the second element;configurations in which the first element is indirectly secured to thesecond element by affixing the first element to intermediate member(s)which in turn are affixed to the second element; and configurations inwhich the first element is integral with the second element; i.e., thefirst element is essentially part of the second element.

As used herein “masking” or “fluid masking” refers to the property of amaterial to mask or make indistinct or imperceptible fluid, menstrualblood or menses that has been carried into the fibers of the absorbentmaterial. As used “masking material” or “material that possess maskingproperties” are materials that have a critical surface tension of lessthan about 40 mN/m, preferably less than about 30 mN/m. “Maskingmaterials” or “materials that possess masking properties” are materials,either wovens, nonowovens, or films, that may be comprised of a blend ofnatural fibers, synthetic fibers or natural and synthetic fibers thatare hydrophobic or a combination of hydrophobic and hydrophilic fiberstreated to be hydrophobic. The natural fibers include rayon, cotton,wood pulp, flax, and hemp. The synthetic fibers can include but are notlimited to fibers such as polyester, polyolefin, nylon, polypropylene,polyethylene, polyacrylic, vinyl polyacetate, polyacrylate, celluloseacetate or bicomponent fibers. The treatments can include but are notlimited to silicones, fatty acids (such as sucrose ester fatty acids),fluorocarbon, such as SCOTCHGUARD, and waxes. One embodiment of themasking overwrap comprises bicomponent fibers of polypropylene andpolyethylene. Another embodiment of the masking overwrap comprisesbicomponent fibers of polyester and polyethylene. One embodiment mayinclude a nonwoven comprised of bicomponent fibers that havepolypropylene core surrounded by polyethylene manufactured byVliesstoffwerke Christian Heinrich Sandler GmbH & Co.KG(Schwarzenbach/Saale, Germany) under the tradename SAS B31812000. Oneembodiment may include a thermally bonded nonwoven of 17 g/m² basisweight manufactured by Vliesstoffwerke Christian Heinrich Sandler GmbH &Co.KG (Schwarzenbach/Saale, Germany) under the tradename Sawabond 4313.

The term “masking region” as used herein refers to the area of theoverwrap that surrounds at least a portion of the compressed absorbentmember proximal to the insertion end of the absorbent member.

As used herein “masking overwrap” refers to the material surrounding atleast a portion of the exterior surface of the compressed absorbentmember, the first surface and the second surface of the absorbentmaterial, and/or the wicking overwrap. The masking overwrap may surroundthe exterior surface of the absorbent member and the first and secondsurface of the absorbent material as well as, any interior surfaces orinterior regions due to the folding or rolling of the absorbent materialduring compression.

As used herein, the term “non-absorbent” refers to a structure that doesnot retain a significant portion of deposited fluid in its structure.

“Overlap” as used herein refers to the ordinary meaning of overlap. Inall embodiments of the present invention “overlap” encompasses bothpartial and complete overlap.

The term “permeating” or “permeates” as used herein refers to the mannerin which the masking overwrap and/or the wicking overwrap are positionedin relation to the inner region of the compressed absorbent member. Asshown in the FIG. 6A and FIG. 6B, the masking overwrap and/or thewicking overwrap extends from the exterior surface and follows thespiral (in the case of rolled) or serpentine (in the case of the folded)contours of the compressed absorbent member and thereby extends into theinner region of the member along the interstices formed by the contoursof the rolls or folds. Any other compression methods are acceptable thatresult in the masking overwrap and/or the wicking overwrap similarlyfollowing the contours of the compressed absorbent member within theinner region. “Substantially permeating” and “substantially permeates”refer to when the masking overwrap and/or the wicking overwrap cover atleast about 50% to about 100% of the surface area of the absorbentmaterial, which after compression becomes the inner region of thecompressed absorbent member.

The term “rolled” as used herein, is the configuration of the compressedabsorbent member after winding the absorbent material and the overwrapor overwraps in a spiral round and round upon itself.

Unless specifically stated otherwise, as used herein a first material is“substantially covering” or “substantially covers” a second materialwhen the first material covers at least about 50% to about 100% of thesurface area of the second material.

The term “surrounds” as used herein refers to the manner in which afirst material covers a second material when the first material coversthe second material and/or when the first material covers a thirdmaterial which covers the second material. In other words, a firstmaterial may “surround” a second material regardless of whether a thirdmaterial or even a fourth material is interposed between the firstmaterial and the second material. For example, for the purposes ofcalculating the percentage of surface area of the exterior surface“surrounded by” the masking overwrap, one would disregard the presenceof wicking overwrap falling between the masking overwrap surface and theexterior surface of the compressed absorbent material. Therefore, asused herein, a first material is “substantially surrounding” or“substantially surrounds” a second material when the first materialcovers from at least about 50% to about 100% of the surface area of thesecond material regardless of whether a third material is interposedbetween the first material and the second material. Thus, an embodimentwhere the wicking overwrap completely covers the exterior surface of theabsorbent member and the masking overwrap covers 100% of the wickingoverwrap would be described as a tampon having a masking overwrap“substantially surrounding” the exterior surface of the absorbentmember. As well, an embodiment where the wicking overwrap completelycovers the first surface and the second surface of the absorbentmaterial and the masking overwrap covers 100% of the wicking overwrapwould be described as a tampon having a masking overwrap “substantiallysurrounding” the first surface and the second surface of the absorbentmaterial.

As used herein, “self-sustaining” is a measure of the degree orsufficiency to which the tampon retains the compression applied to theabsorbent material such that in the subsequent absence of the externalforces, the resulting tampon will tend to retain its general shape andsize. For example, the resulting tampon's total volume growth subsequentto the removal of external forces may be no greater than about 50% ofthe external force-restrained shape, typically less than about 25% andpreferably not to exceed about 10% of the external force-restrainedshape when observed at ambient room conditions of 21–24° C. For tampons,it is found that control of the level of moisture within the tampon is afactor for helping the tampon to retain its shape subsequent the absenceof the external compression forces. In one embodiment, the tampon isself-sustaining if the level of moisture is about 10% and not more thanabout 15%, of the basis weight. It will be understood by one of skill inthe art that this self-sustaining form need not, and preferably does notpersist during actual use of the tampon. That is, once the tampon isinserted and begins to acquire fluid, the tampon will begin to expandand may lose its self-sustaining form.

As used herein the term “tampon” refers to any type of absorbentstructure that is inserted into the vaginal canal or other body cavitiesfor the absorption of fluid therefrom, to aid in wound healing, or forthe delivery of active materials, such as medicaments, or moisture.Tampons have a length, a width, a longitudinal axis and a radial axis.The tampon's length, can be measured from the insertion end to thewithdrawal end along the longitudinal axis. A typical compressed tamponis 30–60 mm in length. A tampon may be straight or non-linear in shape,such as curved along the longitudinal axis. The width of a tampon,unless otherwise stated in the specification, corresponds to the largestcylindrical cross-section along the length. A typical compressed tamponis 8–20 mm wide. The tampon may be compressed into a generallycylindrical configuration in the radial direction, axially along thelongitudinal and lateral axes or in both the radial and axialdirections. While the tampon may be compressed into a substantiallycylindrical configuration, other shapes are possible. These may includeshapes having a cross section that may be described as rectangular,triangular, trapezoidal, semi-circular, hourglass, or other suitableshapes.

As used herein the terms “vaginal cavity,” “within the vagina” and“vaginal interior,” are intended to be synonymous and refer to theinternal genitalia of the human female in the pudendal region of thebody and does not include the interlabial space, including the floor ofvestibule or the externally visible genitalia.

As used herein “wicking” refers to the ability of a material totransport liquid or moisture by capillary action. As used herein“wicking material” or “material that possess wicking properties” arematerials that have the ability to wick deionized water to a height of 3cm in less than 60 seconds when the nonwoven is disposed vertically overa reservoir of water. A method for quantifying such rate is provided inthe Test Method section below. Such “wicking materials” or “materialsthat possess wicking properties” are materials, either wovens,nonowovens, or films, that may comprise a blend of natural fibers,synthetic fibers or natural and synthetic fibers. The wicking region andwicking overwrap are generally more hydrophilic than the absorbentmaterial, absorbent member, the masking region and the masking overwrap.The natural fibers include rayon, cotton, wood pulp, flax, and hemp.Several embodiments of the wicking overwrap or wicking region includeblends comprising from about 25% rayon to about 100% rayon. Oneembodiment includes a 100% rayon material. One embodiment may comprise40 g/m² nonwoven comprising 100% rayon available as SX 275-123 producedby Green Bay Nonwovens, Green Bay, Wis. The synthetic fibers can includebut are not limited to fibers such as polyester, polyolefin, nylon,polypropylene, polyethylene, polyacrylic, vinyl polyacetate,polyacrylate, cellulose acetate or bicomponent fibers. The blend offibers forming the wicking overwrap can be made by any number oftechniques. The blends may be carded on webs. Commonly, carded webs thatare hydroentangled, thermally bonded, and resin bonded all haveapplication. In the latter case, all natural fiber may be used with asignificant portion of binder (10–30% is common). Spunbond and meltblownprocesses, combining synthetic fibers extruded/spun onto/into a mat orcarded web of natural fibers provide other acceptable techniques. Thebasis weight of the material may fall into a range from about 10 toabout 60 grams per square meter, or typically from about 15 to about 40grams per square meter. In one embodiment, wicking material may comprisea hydroentangled blend of 50% rayon, 50% polyester available as BBA140027 produced by BBA Corporation of South Carolina, U.S.A.

The term “wicking region” as used herein refers to the area of theoverwrap that covers at least a portion of the compressed absorbentmember proximal to the withdrawal end of the absorbent member.

As used herein “wicking overwrap” refers to the liquid pervious materialcovering at least a portion of the external surface of the compressedabsorbent member proximal to withdrawal end of the absorbent memberand/or, the first surface and the second surface of the absorbentmaterial. The wicking overwrap optionally extends below the withdrawalend to define a skirt portion.

As used herein, “cm” is centimeter, “mL” is milliliters” “mm” ismillimeters, “mN/m” is milliNewtons per meter, “g” is grams, “g/m²” isgrams per meter squared, and “s” is seconds.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention.

I. Tampon of the Present Invention

The tampon of the present invention comprises an overwrap or overwrapshaving masking and wicking properties. An embodiment of the tampon ofthe present invention with both a masking overwrap 40 and wickingoverwrap 44 is shown in FIG. 1. The compressed absorbent member 22 hasan exterior surface 26 and has an inner region 24 shown in greaterdetail below. The compressed absorbent member 22 has an insertion end 38opposed to a withdrawal end 42. In FIG. 1, the fluid-masking overwrap 40surrounds at least a portion of the exterior surface 26 of thecompressed absorbent member 22. A wicking overwrap 44 covers at least aportion of the exterior surface 26 of the compressed absorbent member 22proximal to the withdrawal end 42. In the embodiment shown in FIG. 1,the wicking overwrap 44 extends beyond over the withdrawal end 42 of thecompressed absorbent member 22 to define a skirt portion 50. In thisembodiment, the masking overwrap 40 and the wicking overwrap 44 overlapsat region 52. As well, this embodiment of the tampon 20 of the presentinvention includes a withdrawal means 48.

FIG. 2 depicts a plan view of an uncompressed tampon including theabsorbent material 28, masking overwrap 40 and wicking overwrap 44. Theabsorbent material 28 that has a first surface 34 opposed to the secondsurface 36 and an insertion end 54 opposed to a withdrawal end 56. Theabsorbent material 28 has both a longitudinal axis and a transverse axisindicated by the lines marked “L” and “T” respectively. The wickingoverwrap 44 is positioned around the absorbent material 28 so that itcovers at least a portion of the first surface 34 and second surface 36proximal to the withdrawal end 56 of the absorbent material 28. In theembodiment shown in FIG. 2, the wicking overwrap 44 extends beyond thewithdrawal end 56 of the absorbent material 28 the to define a skirtportion 50. The masking overwrap 40 surrounds at least a portion of thefirst surface 34 and opposed second surface 36 of the absorbent material28. In the embodiment shown in FIG. 2, the masking overwrap 40 and thewicking overwrap 44 overlap at region 52. In one embodiment, the tampon20 includes a withdrawal means 48. A tampon may be utilized in anuncompressed form. However, to form a compressed tampon, the absorbentmaterial 28, the masking overwrap 40 and the wicking overwrap 44 aretypically compressed and optionally heat conditioned in any suitableconventional manner known in the art.

FIG. 3 shows a longitudinal cross section of an uncompressed tampon ofthe present invention comprising absorbent material 28, masking overwrap40 and wicking overwrap 44 prior to compression. The absorbent material28 has a first surface 34 opposed to the second surface 36. Theabsorbent material 28 is located in the center of the longitudinalcross-section. The masking overwrap 40 is positioned around a portion ofthe first surface 34 of the absorbent material 28 and the second surface36 of the absorbent material 28. The wicking overwrap 44 is positionedaround a portion of the first surface 34 of the absorbent material 28and the second surface 36 proximal to the withdrawal end of theabsorbent material 28. In the embodiment shown in FIG. 3, the maskingoverwrap 40 and the wicking overwrap 44 overlap at region 52.

FIG. 4A is a plan view of the absorbent material 28 with both themasking overwrap 40, and the wicking overwrap 44 wrapped transverselyaround the absorbent material 28. The wicking overwrap 44 is positionedaround the first surface 34 and an opposed second surface 36 proximal tothe withdrawal end 56 of the absorbent material 28 by wrapping aroundthe transverse axis “T” of the absorbent material 28. In the embodimentshown in FIG. 4A, the wicking overwrap 44 extends beyond the withdrawalend 56 of the absorbent material 28 to define a skirt portion 50. In theembodiment shown, the masking overwrap 40 is tranverse around the firstsurface 34 and an opposed second surface 36 by wrapping around thelongitudinal axis “T” of the absorbent material 28. The masking overwrap40 and the wicking overwrap 44 overlap at region 52.

FIG. 4B is a plan view of the absorbent material 28 with the both themasking overwrap 40, and the wicking overwrap 44 wrapped longitudinallyaround the absorbent material 28. FIG. 4B shows an uncompressed tamponcomprising an absorbent material 28, masking overwrap 40, and wickingoverwrap 44. The wicking overwrap 44 is positioned around the firstsurface 34 and the second surface (not shown) proximal to the withdrawalend 42 by wrapping around the longitudinal axis “L” of the absorbentmaterial 28. In the embodiment shown in FIG. 4B, the wicking overwrap 44extends beyond the withdrawal end 56 of the absorbent material 28 todefine a skirt portion 50. The wicking overwrap 44 overlaps with itselfat region 58, as shown to the right of the longitudinal axis “L”. Themasking overwrap 40 is positioned around the first surface 34 and thesecond surface 36 by wrapping around the longitudinal axis “L” of theabsorbent material 28. The masking overwrap 40 overlaps with itself atregion 32, as shown to the right of the longitudinal axis “L”. In theembodiment shown in FIG. 4B, the masking overwrap 40 and the wickingoverwrap 44 overlap at region 52.

FIG. 5A shows an uncompressed tampon comprising the absorbent material28, masking overwrap 40, and wicking overwrap 44. A skirt 50 and awithdrawal means 48 are also shown. FIG. 5A shows a cross-section of thecompressed absorbent member. In the embodiment shown, the compressedabsorbent member was constructed by surrounding at least a portion ofthe absorbent material 28 with the masking overwrap 40, covering atleast a portion of the absorbent material 28 at the withdrawal end witha wicking overwrap 44. The absorbent material 28, masking overwrap 40,wicking overwrap 44 are rolled prior to compression. The resulting crosssection taken proximal to the withdrawal end the tampon, therefore has aspiral of both the masking overwrap 40 and the wicking overwrap 44within the inner region 24 of the compressed absorbent member 22. In theembodiment shown in FIG. 5A, the tampon has a skirt portion 50withdrawal means 48.

FIG. 5B shows a cross-section of the compressed absorbent member. In theembodiment shown, the compressed absorbent member was constructed bysurrounding at least a portion of the absorbent material 28 with themasking overwrap 40, covering at least a portion of the absorbentmaterial 28 at the withdrawal end with a wicking overwrap 44. Theabsorbent material 28 masking overwrap 40, and wicking overwrap 44 arefolded. The resulting cross section taken proximal to the withdrawal endthe tampon, therefore, has a serpentine pattern of both the maskingoverwrap 40 and the wicking overwrap 44 within the inner region 24 ofthe compressed absorbent member. This serpentine pattern can take manyshapes according to the folding process. In the embodiment shown in FIG.5B, the tampon has a skirt portion 50 and withdrawal means 48.

An embodiment of the tampon of the present invention with masking andwicking properties in a single overwrap is shown in FIG. 6. FIG. 6 showsthe tampon 20 of the present invention comprising a compressed absorbentmember 22 and an overwrap 14. The compressed absorbent member 22 of thetampon has an inner region, (not shown in FIG. 6) an exterior surface26, and an insertion end 38 opposed to a withdrawal end 42. The overwrap14 comprises a masking region 16 and a wicking region 18. The wickingregion 18 of the overwrap covers at least a portion of the exteriorsurface 26 of the compressed absorbent member 22 proximal to thewithdrawal end 42 of the compressed absorbent member 22. The maskingregion 16 surrounds at least a portion of the exterior surface 26 of thecompressed absorbent member 22 proximal to the insertion end 38 of thecompressed absorbent member 22.

-   -   a. Absorbent Material

The compressed absorbent member is comprised of absorbent material thathas a first surface 34 opposed to the second surface 36 and an insertionend 54 opposed to a withdrawal end 56. The absorbent material has both alongitudinal axis and a transverse axis indicated by the lines marked“L” and “T” respectively. The absorbent material may be any suitablesize and thickness suitable for compression into a tampon having avaginally insertable shape. In the embodiment shown in FIG. 2, theabsorbent material is generally square or rectangular, but other shapessuch as trapezoidal, triangular, hemispherical, chevron and hourglassshaped are also acceptable. A typical size for absorbent material priorto compression may be from about 40 mm to about 100 mm in length andfrom about 40 mm to about 80 mm in width. The typical range for theoverall basis weight is from about 150 g/m² to about 1000 g/m².

The absorbent material that comprises the compressed absorbent membermay be constructed from a wide variety of liquid-absorbing materialscommonly used in absorbent articles. Such materials include but are notlimited to rayon (such as GALAXY Rayon (a tri-lobed rayon structure)available as 6140 Rayon; or SARILLE L rayon (a round fiber rayon), bothavailable from Acordis Fibers Ltd., of Hollywall, England), cotton,folded tissues, woven materials, nonwoven webs, synthetic and/or naturalfibers or sheeting, comminuted wood pulp which is generally referred toas airfelt, or combinations of these materials. Additional absorbentmaterial include materials, such as peat moss, absorbent foams (such asthose disclosed in U.S. Pat. No. 3,994,298 issued to DesMarais on Nov.30, 1976, U.S. Pat. No. 5,795,921 issued to Dyer, et. al bothincorporated by reference herein,) capillary channel fibers (such asthose disclosed in U.S. Pat. No. 5,356,405 issued to Thompson, et. alincorporated by reference herein), high capacity fibers (such as thosedisclosed in U.S. Pat. No. 4,044,766 issued Kaczmarzk et al. Aug. 30,1977 incorporated by reference herein), superabsorbent polymers orabsorbent gelling materials (such as those disclosed in U.S. Pat. No.5,830,543 issued to Miyake, et al incorporated by reference herein) maybe incorporated into the tampon.

The absorbent material that comprises the compressed absorbent membercan be rectangular or any other shape prior to compression and/orshaping. A more detailed description of liquid-absorbing materialsshapes and dimensions can be found in co-pending case Ser. No.10/039,979, filed Oct. 24, 2001, entitled “Improved Protection andComfort Tampon”, to Agyapong et al.

-   -   b. The Overwrap Material

The tampon of the present invention comprises an overwrap or overwrapshaving masking and wicking properties. One embodiment of the tampon ofthe present invention comprises a tampon comprising an overwrap withboth masking properties and wicking properties, made by treating portionof the overwrap to change the properties of te portions described in the“The Process of Making” section below. Another embodiment of the tamponof the present invention comprises both a masking overwrap and a wickingoverwrap. Unless otherwise noted in this section, “the overwrapmaterial” refers to the overwrap with both masking properties andwicking properties, the masking overwrap and the wicking overwrap. Inall embodiments shown, the overwrap material is generally rectangular,but other shapes such as trapezoidal, triangular, hemispherical,chevron, hourglass shaped, “T” and “L” shaped are also acceptable.Optimally, the overwrap material generally may both correspond to theshape of the absorbent material.

As discussed further in section entitled “Process of Making” theoverwrap material may be wrapped in various configurations around thelongitudinal axis “L” or the transverse axis “T”. Because the overwrapmaterial can be wrapped in the various configurations, the width andlength of the overwrap material may vary. The width of the overwrapmaterial may be wider or less wide than the measure of the longitudinalor transverse axis of the absorbent material it is being wrapped around.As well, the length of the overwrap may be longer or shorter than themeasure of the longitudinal or transverse axis of the absorbent materialit is being wrapped around.

In some embodiments, the overwrap material is wrapped in such a way thatwhen the absorbent material and overwrap are compressed the overwrap maypermeate at least a portion of the inner region of the absorbent memberas discussed further in section entitled “Process of Making”.

The overwrap material may be joined to the absorbent material by anyvariety of means. The overwrap materials may be joined to themselves,another overwrap, the compressed absorbent member or to the absorbentmaterial. For example, one portion of wicking overwrap may be joined toan opposed portion of masking overwrap, wicking overwrap, the compressedabsorbent member, or the absorbent material using any suitable adhesiveor heat/pressure bonding means. Such bonding may extend continuouslyalong the length of attachment or it may be applied in a “dotted”fashion at discrete intervals. Methods of bonding include thermallybonding, fusion bonding, or any other suitable means known in the artfor joining such materials. Alternatively, the wicking overwrap may bejoined to the absorbent material along with the withdrawal cord bystitching as shown in FIG. 3. Such stitching may use natural orsynthetic thread.

A specific example of the tampon the folded compressed tampon of thepresent invention may comprises an absorbent material of 75% rayon and25% cotton fiber with a basis weight of 600 g/m² having dimensions of 60mm in width and 60 mm in length. The tampon may comprise a wickingoverwrap of hydroentangled 50% rayon and 50% polyester fibers with abasis weight of 37 g/m² having dimensions of 110 mm in width and 60 mmin length. The wicking overwrap covers at least a portion of the firstsurface and second surface of the absorbent material. The wickingoverwrap is wrapped around the longitudinal axis of the absorbentmaterial such that 12 mm of the overwrap extends beyond the withdrawalend of the absorbent material. The tampon also comprises a maskingoverwrap of spunbound bicomponent with polyethylene and polypropylenefibers with a basis weigh of 17 g/m² having dimensions of 90 mm in widthand 60 mm in length. The masking overwrap is surrounding at least aportion of the first surface and a second surface of the absorbentmaterial and overlapping the wicking overwrap. The masking overwrap iswrapped around the longitudinal axis of the absorbent material. Theabsorbent material and overwrap are compressed axially andlongitudinally then heated to form a compressed tampon of approximately14 mm diameter and approximately 46 mm length.

-   -   c. Skirt Portion

In some embodiments, either the wicking region of the overwrap or thewicking overwrap may extend beyond the withdrawal end of the absorbentmaterial and the compressed absorbent member to define a skirt portion.In some embodiments, the wicking region or the wicking overwrap mayextend about 5 mm to about 40 mm, or even 2 mm to 25 mm beyond thewithdrawal end defining a skirt portion. In other embodiments, thewicking region or the wicking overwrap may extend about 10 mm to about15 mm beyond the withdrawal end defining a skirt portion. In oneembodiment, the skirt portion may not be compressed. In all embodiments,the skirt is designed to draw bypassed fluid from the bottom of thevagina, thereby increasing absorbency and minimizing bypass discharge.Both the compressed absorbent member and skirt portion of the wickingoverwrap may reside entirely within the vaginal cavity of the wearerduring use of the tampon. This is achieved by the relative closeness ofthe skirt portion to the withdrawal end of the absorbent material aswell of the relative size compared to the overall size of the tampon. Inparticular embodiments, only the withdrawal cord or other withdrawalmeans resides externally to the orifice of the vagina.

-   -   d. Optional Components

Some embodiments of the tampon of the present invention may comprise awithdrawal means. The withdrawal means could be joined to the tampon andgraspable for digital removal after use. In one embodiment, thewithdrawal means may be joined to at least the compressed absorbentmember and extends beyond at least the withdrawal end of the compressedabsorbent member. In another embodiment, the withdrawal means may bejoined to at least the absorbent material and extends beyond at leastthe withdrawal end. Any of the withdrawal means currently known in theart may be used as a suitable withdrawal mechanism. In addition, thewithdrawal means can take on other forms such as a ribbon, loop, tab, orthe like. The withdrawal means may be integral with the absorbentmaterial. Withdrawal cords useful in the present invention may be madeof any suitable material known in the prior art and include cotton andpolyester. Additionally, the tampons of the present invention may alsobenefit from a secondary absorbent member. U.S. Pat. No. 6,258,075 toTaylor et al. entitled “Tampon with Enhanced Leakage Protection”describes tampons having a variety of secondary absorbent members ingreat detail. The withdrawal means may be attached in any suitablemanner known in the art including sewing, adhesive attachment, or acombination of known bonding methods. The withdrawal means may be joinedto any suitable location on the tampon.

The tampon of the present invention may be inserted digitally or throughthe use of an applicator. Any of the currently available tamponapplicators may also be used for insertion of the tampon of the presentinvention. Such applicators of typically a “tube and plunger” typearrangement and may be plastic, paper, or other suitable material.Additionally, a “compact” type applicator is also suitable.

II. Process of Making:

While several methods of making the tampon of the present inventionshould be apparent to one of skill in the art in light of the disclosureherein, following is a description of some methods of making a tampon ofthe present invention.

The present invention relates to a tampon comprising an overwrap oroverwraps with a masking and a wicking region. In some embodiments, oneoverwrap having a masking region and a wicking region are provided. Inother embodiments two separate overwraps (a masking overwrap whichbecomes a masking region and a wicking overwrap which becomes wickingregion) are provided to form the final overwrap (which may or may not bejoined). Whether it is a masking region or a “separate” maskingoverwrap, the masking material may be hydrophobic or may be treated torender the region or overwrap hydrophobic if the starting if material ishydrophilic. Treatments that render a material hydrophobic include butare not limited to applying to or dipping the material in silicones,fatty acids (such as sucrose ester fatty esters), fluorocarbons, such asSCOTCHGUARD, and waxes. Whether it is a wicking region or a wickingoverwrap, the wicking material may be hydrophilic or may treated torender the region or overwrap to be hydrophilic if the starting materialis hydrophobic. Treatments that render a material hydrophilic includebut are not limited to applying or dipping the material in surfactants,including non-ionic surfactants.

In other embodiments where two pieces of material are used to form theoverwrap, a masking material/region/overwrap may be joined to a wickingmaterial/region/overwrap by sewing, adhesives, bonding includingthermally bonding, pressure fusion bonding, or any other suitable meansknown in the art for joining such materials. Alternatively, the twomaterials used to create the overwrap may not be physically connected atall.

In embodiments that begin with providing a compressed absorbent member,the compressed absorbent member has an exterior surface and an innerregion and an insertion end opposed to a withdrawal end. The overwrapmay be wrapped around a longitudinal axis or a transverse axis. Theoverwrap is positioned on the compressed absorbent member such that thewicking region/overwrap covers at least a portion of the exteriorsurface of the compressed absorbent member proximal to the withdrawalend and the masking region/overwrap surrounds at least a portion of theexterior surface of the compressed absorbent member proximal to theinsertion end. In some embodiments, the wicking region/overwrap extendsbeyond the withdrawal end of the compressed absorbent member to define askirt portion. In embodiments that begin with providing a compressedabsorbent member, the overwrap, comprising both the wickingregion/overwrap and the masking region/overwrap, may be joined orapplied to the compressed absorbent member subsequent to compression.Alternatively, a wicking overwrap may be applied prior to compression(discussed further below) and a masking overwrap may be appliedsubsequent to compression. Overwraps applied subsequent to compressionshould be extensible such that the tampon will be able to expand withinthe vagina. The overwrap may be made extensible by processes such as,ring rolling, creping, MICREXing, and SELFing as described in U.S. Pat.No. 5,518,801 issued to Chappell on May 21, 1996, incorporated herein byreference.

Another approach to making tampons of the present invention involveswrapping the absorbent material (which is prior to compression). Theabsorbent material has a first surface opposed to the second surface andan insertion end opposed to a withdrawal end. The overwrap may bewrapped around a longitudinal axis or a transverse axis of the absorbentmaterial. A wrapped absorbent is created by covering at least a portionof the first surface and second surface of the absorbent material withthe wicking region/overwrap proximal to the withdrawal end of theabsorbent material; and surrounding at least a portion of the firstsurface and the second surface of the absorbent material with themasking region/overwrap. In some embodiments, the wickingregion/overwrap may extend beyond the withdrawal end of the absorbentmaterial to define a skirt portion. In some embodiments, the wickingregion/overwrap substantially covers the first surface and the secondsurface of the absorbent material such that the wicking overwrap ispositioned between the exterior surface and the masking region/overwrap.As well, in some embodiments, the masking region/overwrap maysubstantially surround both the first surface and the second surface ofthe absorbent material.

The wrapped absorbent with a skirt is rolled or folded and/or compressedto form a compressed absorbent member having a vaginally insertableshape. Upon compression the masking overwrap surrounds at least aportion of the exterior surface of the compressed absorbent member andmay permeate into the interstices of the inner region of the compressedabsorbent member. Upon compression, the wicking overwrap covers at leasta portion of the exterior surface of the tampon proximal to thewithdrawal end and may permeate at least a portion of the inner regionof the compressed absorbent member. In some embodiments, the maskingoverwrap and/or the wicking overwrap is positioned around the firstsurface and second surface such that when compressed, the maskingoverwrap and the wicking overwrap may substantially permeate the innerregion of the compressed absorbent member subsequent to compression.

III. Test Methods:

-   -   a. Wicking Rate Test:

This test measures how fast a nonwoven material wicks water against theforce of gravity. The nonwoven sample is prepared by cutting anunwrinkled, smooth, straight-hanging piece having dimensions 2.5 cm inwidth and 20 cm in length. The sample is suspended vertically along thelongest dimension using a clip or other attachment device that pinchesonly the uppermost 1 cm or less of the sample. A suitable distancemeasuring device such as a ruler is suspended adjacent to the sample notin direct contact with the sample. An open container of sufficientdimensions is used to hold 300 mL of test fluid. The test fluid isprepared by fully dissolving 0.20 g Indigo Carmine dye (other watersoluble dyes which do not materially change the surface tension of thewater may be used) in 1.00 L of water. The water used in this testing isdeionized water having a surface tension of about 72 mN/m. The test isconducted under ambient conditions approximately 23° C. and 50% relativehumidity. The container is elevated by means of a lab jack or othersuitable device so as to make level contact with the bottom 0.5 cm ofthe hanging test nonwoven strip. Simultaneously with the contact, atiming device is started to measure elapsed time. The level of thewicking front of fluid is recorded for each 10 seconds for a period ofat least about 120 seconds. This is the distance traveled per 10 secondincrement. The test is repeated with a fresh batch of test fluid for 2–3replicates and the appropriately timed data points are averaged andplotted versus time as needed.

A hydrophilic nonwoven will typically wick the test fluid by at leastabout 3 cm in the initial 60 second period, preferably about 4 cm in thesame period. A hydrophobic nonwoven will not wick fluid at all. Ahydrophobic nonwoven may show a nonwetting meniscus at the point ofcontact with the fluid characteristic of a contact angle greater than75°.

-   -   b. Critical Surface Tension:

The critical surface tension of the hydrophobic nonwoven may beapproximated by reducing the surface tension of the test liquid byaddition of a surfactant to the point where the sample can wick thefluid to a height of about 5 cm in about 10 minutes according to theWicking Rate Test above. The surface tension of the test fluid can atthat point be measured by any suitable device (surface tensiometer). Thesurface tension approximates the critical surface tension of thenonwoven.

Average Distance Traveled by Time Test Fluid Material (s) (mm) Anembodiment of the masking overwrap 10 0 comprising a nonwoven comprisedof 20 0 bicomponent fibers under tradename SAS 30 0 B31812000manufactured by Vliesstoffwerke 40 0 Christian Heinrich Sandler GmbH &Co. KG 50 0 (Schwarzenbach/Saale, Germany) 60 0 An embodiment of thewicking overwrap 10 21 comprising a hydroentangled blend of 50% rayon,20 28 50% polyester available as BBA 140027 30 35 produced by BBACorporation of South Carolina, 40 39 U.S.A. 60 44 An embodiment of thewicking overwrap 10 26 comprising 40 g/m² nonwoven comprising 100% 20 38rayon available as SX 275-123 produced by 30 45 Green Bay Nonwovens,Green Bay, WI. 40 50 60 62

All documents cited in the Detailed Description of the Invention are, inrelevant part, incorporated by reference herein; the citation of anydocument is not to be construed as an admission that it is prior artwith respect to the present invention. To the extent that any meaning ordefinition of the term in this written document conflicts with anymeaning or definition of the term in a document incorporated byreference, the meaning or definition assigned to the term in thiswritten document shall govern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

1. A tampon comprising: a compressed absorbent member having an innerregion and an exterior surface; and an insertion end opposed to awithdrawal end; an overwrap comprising a masking region and a wickingregion; said wicking region of said overwrap covering at least a portionof said exterior surface of said compressed absorbent member proximal tothe withdrawal end of said compressed absorbent member; said maskingregion surrounding at least a portion of said exterior surface of saidcompressed absorbent member proximal to said insertion end of saidcompressed absorbent member; wherein said wicking region of saidoverwrap is comprised of a material that has the ability to transportliquid or moisture by capillary action; and wherein said masking regionis comprised of a material that that has a critical surface tension ofless than about 40 mN/m.
 2. A tampon according to claim 1 wherein theoverwrap comprises a blended material selected from the group consistingof natural fibers and synthetic fibers and mixtures thereof.
 3. A tamponaccording to claim 1 wherein the masking region is treated to behydrophobic.
 4. A tampon according to claim 3 wherein the hydrophobictreatments are selected from the group consisting of silicone, fattyacids, fluorocarbons, waxes and mixtures thereof.
 5. A tamponcomprising: a compressed absorbent member having an inner region and anexterior surface and an insertion end opposed to a withdrawal end; awicking overwrap covering at least a portion of said exterior surface ofsaid compressed absorbent member proximal to the withdrawal end of saidabsorbent member; said wicking overwrap permeating at least a portion ofsaid inner region of said compressed absorbent member; a maskingoverwrap surrounding at least a portion of said exterior surface of saidcompressed absorbent member; wherein said wicking region of saidoverwrap is comprised of a material that has the ability to transportliquid or moisture by capillary action; and wherein said masking regionis comprised of a material that that has a critical surface tension ofless than about 40 mN/m.
 6. A tampon according to claim 5 wherein saidwicking overwrap extends beyond the withdrawal end of said absorbentmember to define a skirt portion.
 7. A tampon according to claim 6wherein said skirt portion extends from about 10 mm to about 15 mm fromsaid withdrawal end of said absorbent material.
 8. A tampon according toclaim 5 wherein said wicking overwrap substantially covers said exteriorsurface of said compressed absorbent member such that said wickingoverwrap is positioned between the exterior surface and said maskingoverwrap.
 9. A tampon according to claim 5 wherein the masking overwrapcomprises a nonwoven material comprising a blend of synthetic fibers.10. A tampon according to claim 5 wherein the masking overwrap comprisesa nonwoven-material comprising synthetic fibers selected from the groupsconsisting of polyester, polyolefin, nylon, polypropylene, polyethylene,polyacrylic, vinyl polyacetate, polyacrylate, cellulose acetate,bicomponent fibers polyester, and mixtures thereof.
 11. A tamponaccording to claim 5 wherein said wicking overwrap comprises a nonwovenmaterial comprising from about 25% to about 100% rayon.
 12. A tamponaccording to claim 5 wherein a withdrawal means is attached to saidcompressed absorbent member and extends beyond said withdrawal end.